U.S. patent number 6,083,594 [Application Number 09/167,783] was granted by the patent office on 2000-07-04 for pre-cut fibrous insulation for custom fitting wall cavities of different widths.
This patent grant is currently assigned to Johns Manville International, Inc.. Invention is credited to Robert J. Allwein, John A. Fry, William H. Olbert, Vern C. Plotts, Jo M. Teague, Larry J. Weinstein.
United States Patent |
6,083,594 |
Weinstein , et al. |
July 4, 2000 |
Pre-cut fibrous insulation for custom fitting wall cavities of
different widths
Abstract
A fibrous insulation blanket is pre-cut for custom fitting the
insulation blanket into structural framework building cavities of
different widths. The width of the blanket is substantially equal
to the width of a standard cavity to be insulated by the blanket
and the blanket has one or more longitudinally extending cuts in a
first major surface of the blanket. The cut(s) have a depth greater
than one half of the thickness of the blanket and less than the
thickness of the blanket whereby the blanket can be handled as a
unit for insulating a cavity having a standard cavity width or
easily torn apart at a cut by hand for insulating a cavity having
less than a standard cavity width. The second major surface of the
blanket may have a facing bonded thereto with one or more
perforated lines in the facing aligned with the cut(s) to
facilitate tearing apart the blanket by hand if required.
Preferably, the perforations of the perforated line(s) are closed
by the bonding agent bonding the facing to the blanket so that the
facing functions as a vapor barrier in spite of the
perforations.
Inventors: |
Weinstein; Larry J. (Littleton,
CO), Allwein; Robert J. (Littleton, CO), Fry; John A.
(Conifer, CO), Plotts; Vern C. (Littleton, CO), Teague;
Jo M. (Littleton, CO), Olbert; William H. (Littleton,
CO) |
Assignee: |
Johns Manville International,
Inc. (Denver, CO)
|
Family
ID: |
22608814 |
Appl.
No.: |
09/167,783 |
Filed: |
October 7, 1998 |
Current U.S.
Class: |
428/43; 428/167;
52/404.1; 52/98 |
Current CPC
Class: |
B32B
5/26 (20130101); B32B 38/04 (20130101); E04B
1/7662 (20130101); E04B 1/767 (20130101); B32B
2038/047 (20130101); B32B 2307/304 (20130101); B32B
2395/00 (20130101); Y10T 156/1064 (20150115); E04B
2001/741 (20130101); E04B 2001/7695 (20130101); Y10T
428/2457 (20150115); Y10T 156/1082 (20150115); Y10T
428/15 (20150115) |
Current International
Class: |
B32B
38/04 (20060101); B32B 5/22 (20060101); B32B
5/26 (20060101); E04B 1/76 (20060101); E04B
1/74 (20060101); B32B 003/00 () |
Field of
Search: |
;428/43,167
;52/404.1,98,404.4 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Thomas; Alexander
Attorney, Agent or Firm: Touslee; Robert D.
Claims
What is claimed is:
1. A fibrous insulation blanket pre-cut for custom fitting the
insulation blanket into structural framework building cavities of
different widths, comprising:
a fibrous insulation blanket; the fibrous insulation blanket having
a length, a width and a thickness; the length of the fibrous
insulation blanket being at least three times the width of the
fibrous insulation blanket; the width of the fibrous insulation
blanket being substantially equal to the width of a standard cavity
to be insulated; the fibrous insulation blanket having a first
major surface and a second major surface; the fibrous insulation
blanket having a first cut in the first major surface of the
fibrous insulation blanket extending for the length of the fibrous
insulation blanket; the first cut having a depth, extending to
within one quarter of an inch of the second major surface of the
fibrous insulation blanket, that is greater than one half of the
thickness of the fibrous insulation blanket and less than the
thickness of the fibrous insulation blanket whereby the fibrous
insulation blanket can be handled as a unit for insulating a cavity
having a standard cavity width or easily torn apart at the first
cut by hand for insulating a cavity having less than a standard
cavity width.
2. The pre-cut fibrous insulation blanket according to claim 1,
wherein: the standard cavity width is about fifteen inches and the
width of the fibrous insulation blanket is about fifteen
inches.
3. The pre-cut fibrous insulation blanket according to claim 1,
wherein: the fibrous insulation blanket is a resilient glass fiber
insulation blanket.
4. The pre-cut fibrous insulation blanket according to claim 1,
wherein: the fibrous insulation blanket has a second cut in the
first major surface extending parallel to the first cut and
extending for the length of the fibrous insulation blanket; the
second cut having a depth greater than one half of the thickness of
the fibrous insulation blanket and less than the thickness of the
fibrous insulation blanket whereby the fibrous insulation blanket
can be handled as a unit for insulating a cavity having a standard
cavity width or easily torn apart at either the first or second cut
by hand for insulating a cavity having less than a standard cavity
width.
5. A fibrous insulation blanket pre-cut for custom fitting the
insulation blanket into structural framework building cavities of
different widths,
comprising:
a fibrous insulation blanket; the fibrous insulation blanket having
a length, a width and a thickness; the length of the fibrous
insulation blanket being at least three times the width of the
fibrous insulation blanket; the width of the fibrous insulation
blanket being substantially equal to a width of a standard cavity
about fifteen inches wide; the fibrous insulation blanket having a
first major surface and a second major surface;
the fibrous insulation blanket having a first cut in the first
major surface of the fibrous insulation blanket extending for the
length of the fibrous insulation blanket; the first cut having a
depth greater than one half of the thickness of the fibrous
insulation blanket and less than the thickness of the fibrous
insulation blanket;
the fibrous insulation blanket having a second cut in the first
major surface of the insulating blanket extending for the length of
the fibrous insulation blanket and parallel to the first cut; the
second cut having a depth greater than one half of the thickness of
the fibrous insulation blanket and less than the thickness of the
fibrous insulation blanket; and
the first and second cuts dividing the fibrous insulation blanket
into three sections about three and one half inches, about five
inches, and about six and one half inches wide, respectively
whereby the fibrous insulation blanket can be handled as a unit for
insulating a cavity having a standard cavity width or easily torn
apart at either the first or second cut by hand for insulating a
cavity having less than a standard cavity width.
6. The pre-cut fibrous insulation blanket according to claim 5,
wherein: the five inch wide section is the midsection of the three
sections.
7. The pre-cut fibrous insulation blanket according to claim 5,
wherein: the fibrous insulation blanket is a resilient glass fiber
insulation blanket.
8. A fibrous insulation blanket pre-cut for custom fitting the
insulation blanket into structural framework building cavities of
different widths, comprising:
a fibrous insulation blanket; the fibrous insulation blanket having
a length, a width and a thickness; the length of the fibrous
insulation blanket being at least three times the width of the
fibrous insulation blanket; the width of the fibrous insulation
blanket being substantially equal to the width of a standard cavity
to be insulated; the fibrous insulation blanket having a first
major surface and a second major surface;
the fibrous insulation blanket having a first cut in the first
major surface of the fibrous insulation blanket extending for the
length of the fibrous insulation blanket; the first cut having a
depth greater than one half of the thickness of the fibrous
insulation blanket and less than the thickness of the fibrous
insulation blanket; and
a facing sheet overlying the entire second major surface of the
fibrous insulation blanket and being bonded to the second major
surface of the fibrous insulation blanket; and the facing sheet
having a first perforated line therein extending for the length of
the fibrous insulation blanket and aligned with the first cut in
the fibrous insulation blanket whereby the fibrous insulation
blanket with the facing can be handled as a unit for insulating a
cavity having a standard cavity width or easily torn apart at the
first cut and the aligned first perforated line by hand for
insulating a cavity having less than a standard cavity width.
9. The pre-cut fibrous insulation blanket according to claim 8,
wherein: the perforations of the first perforated line are filled
with a bonding agent that bonds the facing sheet to the second
major surface of the fibrous insulation blanket to close the
perforations so that the facing sheet functions as a vapor
barrier.
10. The pre-cut fibrous insulation blanket according to claim 8,
wherein: the fibrous insulation blanket is a resilient glass fiber
insulation blanket.
11. A fibrous insulation blanket pre-cut for custom fitting the
insulation blanket into structural framework building cavities of
different widths, comprising:
a fibrous insulation blanket; the fibrous insulation blanket having
a length, a width and a thickness; the length of the fibrous
insulation blanket being at least three times the width of the
fibrous insulation blanket; the width of the fibrous insulation
blanket being substantially equal to the width of a standard cavity
to be insulated; the fibrous insulation blanket having a first
major surface and a second major surface;
the fibrous insulation blanket having a first cut in the first
major surface of the fibrous insulation blanket extending for the
length of the fibrous insulation blanket; the first cut having a
depth greater than one half of the thickness of the fibrous
insulation blanket and less than the thickness of the fibrous
insulation blanket;
the fibrous insulation blanket having a second cut in the first
major surface extending for the length of the fibrous insulation
blanket and parallel to the first cut; the second cut having a
depth greater than one half of the thickness of the fibrous
insulation blanket and less than the thickness of the fibrous
insulation blanket; and
a facing sheet overlying the entire second major surface of the
fibrous insulation blanket and being bonded to the second major
surface of the fibrous insulation blanket; and the facing sheet
having first and second perforated lines therein extending for the
length of the fibrous insulation blanket and aligned with the first
and second cuts in the fibrous insulation blanket whereby the
fibrous insulation blanket with the facing can be handled as a unit
for insulating a cavity having a standard cavity width or easily
torn apart at either the first or second cut and the aligned first
or second perforated line by hand for insulating a cavity having
less than a standard cavity width.
12. The pre-cut fibrous insulation blanket according to claim 11,
wherein: the perforations of the first and second perforated lines
are filled with a bonding agent that bonds the facing sheet to the
second major surface of the fibrous insulation blanket to close the
perforations so that the facing sheet functions as a vapor
barrier.
13. The pre-cut fibrous insulation blanket according to claim 12,
wherein: the standard cavity width is about fifteen inches and the
width of the fibrous insulation blanket is about fifteen inches;
and the first and second cuts and perforated lines divide the
fibrous insulation blanket into three sections about three and one
half inches, about five inches, and about six and one half inches
respectively.
14. The pre-cut fibrous insulation blanket according to claim 13,
wherein: the five inch wide section is the midsection of the three
sections.
15. The pre-cut fibrous insulation blanket according to claim 11,
wherein: the fibrous insulation blanket is a resilient glass fiber
insulation blanket.
Description
BACKGROUND OF THE INVENTION
The present invention relates to a fibrous insulation blanket
pre-cut for custom fitting the blanket into both standard and
non-standard width structural framework building cavities, such as
wall cavities; and, in particular, to such a blanket that can be
handled as a unit when insulating standard width cavities or easily
torn apart (by hand) along the cuts to form narrower blankets when
insulating less than standard width cavities.
Building structures, such as residential houses, industrial
buildings, office buildings, mobile homes, prefabricated buildings
and similar structures typically include walls (both interior and
exterior), ceilings, floors and roofs which are insulated for both
thermal and acoustical purposes, especially the exterior walls and
the roofs of such structures. The walls, ceilings, floors and roofs
of these structures include framing members, e.g. studs, rafters,
joists, beams and similar support members, which are normally
spaced-apart standard distances, and to which sheathing, paneling,
lathing or similar construction materials are secured to form the
walls, ceilings, floors and roofs. While the contractor seeks to
maintain the spacing of such framing members in these structures at
these standard distances for ease of construction and insulation of
the elongated cavities formed in these walls, ceilings, floors, and
roofs, frequently the walls, ceilings, floors and/or roofs of these
structures include elongated cavities defined, at least in part, by
adjacent framing members which are spaced apart a nonstandard
distance less than the standard spacing between framing members.
Studies have shown that in a typical residential house, it is
common for 50% or more of the framing members in the exterior walls
of these structures to be spaced apart at nonstandard distances
less than the standard spacing for such framing members.
When insulating these elongated cavities of various nonstandard
widths, less than a standard width, it has been the practice to
take an insulation batt preformed to fit the standard cavity width
and reduce the width of the insulation batt by cutting off and
removing a strip of insulation material from one or both
longitudinal edges of the insulation batt. U.S. Pat. No. 5,331,787;
issued Jul. 26, 1994; to Kaarst; illustrates this approach. In the
invention of this patent, the insulation batts or panels have
widths at least equal to a predetermined maximum distance between
adjacent support members defining the cavities that the batts or
panels are to insulate. The batts or panels are provided with
facings that are folded over along the longitudinal edges of the
batts or panels so that strips of insulation material can be cut
away from one or both longitudinal edges of the batts or panels to
fit the batts or panels between support members spaced apart less
than the predetermined maximum spacing. This method of trimming the
insulation batts at the job site by cutting the batts to fit
between the more closely spaced support members is time consuming,
raises a significant risk or safety issue, relies heavily on the
worker's skill to accurately trim the batt or panel.
U.S. Pat. No. 4,866,905; issued Sep. 19, 1989; to Bihy et al;
discloses another approach to the problem. In the invention
disclosed in this patent, a continuous strip of fibrous insulation
with transverse marking lines is provided. The worker cuts the
strip of fibrous insulation at the job site to a width somewhat
greater than the spacing between the framing members, i.e. rafters,
defining the space to be insulated. Of course this method of
forming insulation batts or panels at the job site is also time
consuming and relies heavily on the skill of the worker cutting the
insulation strip to achieve a good result.
A different approach to the problem is shown in U.S. Pat. No.
2,335,968; issued Dec. 7, 1943; to Sawtell. In the invention of
this patent, the lateral edges of the insulation blanket are turned
down to enable the insulation batt to be placed between framing
members, i.e. rafters, spaced closer together than the width of the
insulation batt. This approach does not require any cutting or
trimming at the job site, but it can be used only where the spacing
between the framing members is slightly less than the width of
insulation blanket.
Thus it can be seen that there has been a need to provide fibrous
insulation blankets or batts which can be used to either insulate
standard width framework cavities or be quickly and easily reduced
in width to fit less than standard width cavities without a need to
cut the fibrous insulation blankets at the job site with knives or
similar cutting tools.
SUMMARY OF THE INVENTION
The fibrous insulation blanket of the present invention provides a
solution to the above discussed problems. The fibrous insulation
blanket of the present invention is pre-cut for custom fitting the
insulation blanket into structural framework building cavities of
different widths. The width of the blanket is equal to or
substantially equal to the width of a standard cavity to be
insulated by the blanket, e.g. fifteen inches for a wall cavity,
and the blanket has one or more longitudinally extending cuts in a
first major surface of the blanket. The cut(s) have a depth greater
than one half of the thickness of the blanket and less than the
thickness of the blanket whereby the blanket can be handled as a
unit for insulating a cavity having a standard cavity width or
easily torn apart at a cut by hand for insulating a cavity having
less than a standard cavity width.
The second major surface of the blanket may have a facing bonded
thereto with one or more perforated lines in the facing aligned
with the cut(s) in
the blanket to facilitate tearing apart the faced blanket by hand,
if required. Preferably, the perforations of the perforated line(s)
are closed by the bonding agent (typically, asphalt or other
another bituminous material) bonding the facing to the blanket so
that the facing functions as a vapor barrier in spite of the
perforations. Thus, the fibrous insulation blanket with the facing
can still be quickly and easily modified to fit a cavity of a
particular width without sacrificing the vapor barrier properties
of the facing sheet.
With the pre-cut fibrous insulation blanket of the present
invention, the blanket can be quickly and easily sized to fit wall
or other building framework cavities without the need to use
cutting tools at the job site to cut the insulation. Thus, the use
of the pre-cut fibrous insulation blanket of the present invention
to insulate the framework cavities of buildings, especially wall
cavities, not only reduces safety concerns, but greatly speeds up
the installation process. Since insulation installers are
frequently paid by the piece, the present invention enables them to
operate more profitably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevation of the frame of an outside wall of
a building with the pre-cut fibrous insulation blanket of the
present invention installed in standard width and less than
standard width structural framework wall cavities.
FIG. 2 is a schematic view of a major surface of an unfaced pre-cut
fibrous insulation blanket of the present invention.
FIG. 3 is a schematic end view of the unfaced pre-cut fibrous
insulation blanket of FIG. 2.
FIG. 4 is a schematic view of a first major surface of a faced
pre-cut fibrous insulation blanket of the present invention.
FIG. 5 is a schematic end view of the faced pre-cut fibrous
insulation blanket of FIG. 4.
FIG. 6 is a schematic view of a faced, second major surface of the
faced, pre-cut fibrous insulation blanket of FIG. 4.
FIG. 7 is a schematic plan view of a production line for making the
pre-cut fibrous insulation blanket of the present invention.
FIG. 8 is a schematic side elevation of the production line of FIG.
7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a portion of a typical outside wall of a residential
house with the pre-cut fibrous insulation blanket 20 of the present
invention installed in both standard width and non-standard width
wall cavities of the outside wall. The widths of the wall cavities
are defined by the framing members 22 which are spaced apart a
standard distance for standard cavities 24, e.g. fifteen inches for
an outside wall cavity, or less than the standard distance for
non-standard width cavities 26.
While the pre-cut fibrous insulation blanket 20 may be made of
other fibrous materials, preferably the pre-cut fibrous insulation
blanket 20 is made of glass fibers. In addition, the pre-cut
fibrous insulation blanket 20 is preferably resilient so that,
after being compressed to insert the pre-cut fibrous insulation
blanket or section(s) of the pre-cut fibrous insulation blanket
into a cavity having a width somewhat less than the width of the
pre-cut fibrous insulation blanket or the sections of the pre-cut
fibrous insulation blanket being inserted into the cavity, the
pre-cut fibrous insulation blanket 20 or one or more sections of
the pre-cut fibrous insulation blanket 20 inserted into the cavity
will expand to the width of a cavity.
Typically, for most applications such as walls in residential
houses, the resilient, pre-cut fibrous insulation blankets 20 of
the present invention will be delivered to the installer in roll
form of various lengths greater than that of a standard fibrous
insulation batt or as standard length batts having lengths of about
forty-eight or ninety-three inches. The width of the fibrous
insulation blanket 20 is substantially equal to or equal to the
standard cavity width to be insulated with the fibrous insulation
blanket, e.g. about fifteen inches wide for a fibrous insulation
blanket used to insulate outside wall cavities of residential
houses. The thicknesses of the pre-cut fibrous insulation blankets
20 is determined by the amount of thermal resistance or sound
control desired and the depth of the cavities being insulated.
Typically, the thickness of the fibrous insulation blanket
approximates the depth of the cavities being insulated. For
example, in a wall cavity defined in part by nominally 2.times.4 or
2.times.6 inch studs or framing members, the pre-cut fibrous
insulation blankets will have thicknesses of about three and
one-quarter or three and one-half inches and about five and
one-half inches respectively.
FIGS. 2 and 4 show an unfaced embodiment of the fibrous insulation
blanket 20 of the present invention. The fibrous insulation blanket
has a length "L", a width "W" and a thickness "T". When used to
insulate wall cavities, the length of the fibrous insulation
blanket is typically at least three times the width of the fibrous
insulation blanket, e.g. fifteen inches wide and about forty eight
or ninety three inches in length. The width of the fibrous
insulation blanket is equal to or substantially equal to the width
of a standard cavity to be insulated.
The pre-cut fibrous insulation blanket 20 has a first major surface
30 and a second major surface 32. There are one or more cuts,
preferably two cuts 34 and 36, in the first major surface 30 of the
pre-cut fibrous insulation blanket which divide the pre-cut fibrous
insulation blanket 20 into two or more sections, preferably three
sections 38, 40 and 42, extending the length of the pre-cut fibrous
insulation blanket. Preferably, for a pre-cut fibrous insulation
blanket having a width of about fifteen inches, the sections 38, 40
and 42 are about three and one-half, five, and six and one-half
inches wide.
Each of the cuts 34 and 36 extend for the length of the fibrous
insulation blanket and have a depth greater than one half of the
thickness of the fibrous insulation blanket but less than the
thickness of the fibrous insulation blanket whereby the fibrous
insulation blanket can be handled as a unit for insulating a cavity
24 having a standard cavity width or easily torn apart at one or
more of the cuts 34 and/or 36 by hand (without the use of a knife
or other cutting tool) for insulating a cavity 26 having less than
a standard cavity width. Preferably, the cut or cuts 34 and 36 in
the first major surface 30 of the pre-cut fibrous insulation
blanket 20 extend to within one-quarter of an inch of the second
major surface 32, but, as stated above, not to the second major
surface.
FIGS. 4-6 show a faced embodiment 120 of the pre-cut fibrous
insulation blanket. The faced embodiment of the pre-cut fibrous
insulation blanket 120 is the same as the unfaced embodiment with
the following exceptions: the faced embodiment 120 of the pre-cut
fibrous insulation blanket includes a facing 150 and a bonding
agent 152 which bonds the facing 150 to the second major surface
132 of the pre-cut fibrous insulation blanket.
As shown, the pre-cut fibrous insulation blanket 120 of FIGS. 4-6
has a first major surface 130 and a second major surface 132. There
are one or more cuts, preferably two cuts 134 and 136, in the first
major surface 130 of the pre-cut fibrous insulation blanket which
divide the pre-cut fibrous insulation blanket 120 into two or more
sections, preferably three sections 138, 140 and 142, extending the
length of the pre-cut fibrous insulation blanket. Preferably, for a
pre-cut fibrous insulation blanket having a width of about fifteen
inches, the sections 138, 140 and 142 are about three and one-half,
five, and six and one-half inches wide.
Each of the cuts 134 and 136 extend for the length of the fibrous
insulation blanket 120 and have a depth greater than one half of
the thickness of the fibrous insulation blanket but less than the
thickness of the fibrous insulation blanket whereby the fibrous
insulation blanket can be handled as a unit for insulating a cavity
24 having a standard cavity width or easily torn apart at one or
more of the cuts 134 and/or 136 by hand for insulating a cavity 26
having less than a standard cavity width. Preferably, the cut or
cuts 134 and 136 in the first major surface 130 of the pre-cut
fibrous insulation blanket 120 extend to within one-quarter of an
inch of the second major surface 132, but, as stated above, not to
the second major surface.
The facing or facing sheet 150 overlies the entire second major
surface 132 of the pre-cut fibrous insulation blanket 120 and is
bonded to the second major surface of the pre-cut fibrous
insulation blanket. As shown, the facing sheet 150 has first and
second perforated lines 154 and 156 therein extending for the
length of the pre-cut fibrous insulation blanket. The perforated
lines 154 and 156 are longitudinally aligned with the first and
second cuts 134 and 136, respectively, in the pre-cut fibrous
insulation blanket whereby the pre-cut fibrous insulation blanket
120 with the facing 150 can be handled as a unit for insulating a
cavity having a standard cavity width or easily torn apart at
either the first or second cut 134 or 136 and the aligned first or
second perforated line 154 or 156 by hand (without the use of a
knife or other cutting tool) for insulating a cavity having less
than a standard cavity width. The spaced apart perforations of the
perforated lines 154 and 156 may be of various shapes, including
but not limited to, round, oval, elongated, slit shaped, etc.
Preferably, the perforations of the first and second perforated
lines 154 and 156 are filled with the bonding agent 152 that bonds
the facing sheet 150 to the second major surface 132 of the pre-cut
fibrous insulation blanket to close the perforations so that the
facing sheet 150 functions as a vapor barrier. Preferably, the
bonding agent is an asphalt or other bituminous material that can
be applied to one side of the previously perforated facing sheet
150 just prior to applying the facing sheet to the pre-cut fibrous
insulation blanket.
The preferred different widths of the sections 38, 40 and 42 or
sections 138, 140 and 142, enable the pre-cut fibrous insulation
blanket 20 or 120 to be quickly and easily formed into widths of
about three and one-half inches (section 38 or 138), five inches
(section 40 or 140), six and one-half inches (section 42 or 142),
eight and one-half inches (sections 38 and 40 or 138 and 140) and
eleven and one-half inches (sections 40 and 42 or 140 and 142).
Thus, the pre-cut fibrous insulation blanket 20 or 120 can not only
be used to insulate cavities having standard widths, but the width
of the pre-cut fibrous insulation blanket can also be quickly and
easily modified to fit cavities of various non-standard widths. The
use of a resilient fibrous insulation blanket 20 or 120, such as a
resilient glass fiber insulation blanket, further enhances the
ability of the pre-cut fibrous insulation blanket to conform to
various cavity widths.
FIGS. 7 and 8 schematically show a preferred method of making the
unfaced or faced pre-cut fibrous insulation blanket 20 or 120.
According to the method of the present invention a fibrous
insulation blanket of the appropriate width, e.g. fifteen inches
wide for wall cavities, is fed through a cutting station 160 where
rotary saws or other conventional cutting means form one or more
cuts 34 and 36 or 134 and 136 in the first major surface 30 or 130
of the fibrous insulation blanket as the fibrous insulation blanket
passes through the cutting station. The cut(s) formed have a depth
greater than one half of the thickness of the fibrous insulation
blanket but less than the thickness of the fibrous insulation
blanket whereby the fibrous insulation blanket can be handled as a
unit or easily torn apart at the cut(s) by hand without the use of
a knife or other cutting tool. When the fibrous insulation blanket
is to be faced, the pre-cut fibrous insulation blanket 120 is then
fed into a facing station 162.
A facing or facing sheet 150 with one or more longitudinally
extending perforated line(s) 154 and 156 extending for the length
of the facing is fed from a supply roll 164. At a bonding agent
application station 166 a bonding agent 152, such as but not
limited to hot asphalt or another bituminous material, is applied
to an upper major surface of the facing sheet 150 for bonding the
facing sheet 150 to the second major surface 132 of the pre-cut
fibrous insulation blanket 120 and for closing the perforations of
the perforated line(s) 154 and 156 so that the facing sheet 150
functions as a vapor barrier in spite of the perforations in the
facing sheet. The major surface of the facing sheet with the
bonding agent thereon is then brought into contact with the second
major surface 132 of the fibrous insulation blanket with the
perforated line(s) 154 and 156 longitudinally aligned with the
cut(s) 134 and 136 in the pre-cut fibrous insulation blanket 120
and the facing sheet 150 is bonded to the pre-cut fibrous
insulation blanket 120 whereby the faced fibrous insulation blanket
formed can be handled as a unit for insulating a cavity having a
standard cavity width or easily torn apart at a cut and the aligned
perforated line by hand (without the use of a knife or other
cutting tool) for insulating a cavity having less than a standard
cavity width. The pre-cut faced fibrous insulation blanket 120 is
then formed into a roll 168, as shown, or cut transversely into
selected lengths, e.g. forty eight or ninety three inch lengths to
form batts.
In describing the invention, certain embodiments have been used to
illustrate the invention and the practices thereof. However, the
invention is not limited to these specific embodiments as other
embodiments and modifications within the spirit of the invention
will readily occur to those skilled in the art on reading this
specification. Thus, the invention is not intended to be limited to
the specific embodiments disclosed, but is to be limited only by
the claims appended hereto.
* * * * *